Binghamton - Johnson City Joint Sewage Treatment Plant Rehabilitation Project
In September 2011, significant flooding associated with Tropical Storm Lee inundated the Binghamton – Johnson City Joint Sewage Treatment Plant (BJCJSTP or Plant) and key equipment throughout the entire facility was damaged, including significant damage to the Biological Aerated Filter (BAF) facilities. Since 2011, much of the BJCJSTP has been inoperable or performing poorly due to process system failures, BAF structure failure, Tropical Storm Lee flood damage, and general age/wear of process equipment.
Just recently, an Order on Consent was negotiated between the City of Binghamton, the Village of Johnson City, the Joint Sewage Board and the NYSDEC to develop a plan to restore treatment operations at the BJCJSTP. The Order on Consent requires that construction be substantially complete by August 1, 2018, fully complete by March 1, 2019, and that the Plant be meeting the SPDES Permit discharge limits by May 1, 2019.
The principal goal of this restoration and rehabilitation project at the BJCJSTP is to reconstruct a functioning, automated secondary treatment process using a BIOSTYR system that can meet the SPDES Permit discharge limits. Integral to the BIOSTYR system are other processes that must also be reconstructed or upgraded; for example headworks and primary clarification upstream of the BIOSTYR system, and disinfection and solid handling down-stream of the BIOSTYR system.
The Binghamton – Johnson City Joint Sewage Treatment Plant (BJCJSTP) is a 60 million gallon per day (MGD) wastewater treatment facility that is jointly owned by the City of Binghamton and the Village of Johnson City and managed by the Binghamton – Johnson City Joint Sewage Board (BJCJSB).
The BJCJSTP suffered a structural failure in May 2011 and severe damage in the flood of September 2011. Accordingly, an Order on Consent was negotiated between the City of Binghamton, the Village of Johnson City, the BJCJSB and the NYSDEC to develop a plan to restore treatment operations at the BJCJSTP. The Order on Consent requires that the Secondary Treatment Process construction be complete by August 1, 2018 to allow treatment of 35 MGD, and for the remainder of the secondary treatment to be operable by May 1, 2019. In accordance with the Consent Order, the sewage treatment plant must be fully operable by May, 1, 2019.
The project is being constructed in accordance with Wicks Law which requires that the project be divided into four individual contracts. A General Civil Construction Contract, an Electrical Contract, an HVAC Contract and also a Plumbing Contract. The following projects are either nearing completion, in construction, or in the planning stage.
Contract No. 1 - Compost Facility Demolition – nearing final completion
Contract No. 2 – FEMA Mechanical – Substantial Completion Date July 2016
Contract No. 3 – BAF Facility Demolition – nearing final completion
Contract No. 4 – MCC – HH Emergency Replacement – substantial completion in September 2016
Contract No. 5 – BAF Restoration and Rehabilitation Civil Contract – Notice to Proceed (NTP) - Issued May 27, 2016
Contract No. 6 – BAF Electrical – NTP Issued May 27, 2016
Contract No. 7—BAF HVAC – NTP Issued May, 27, 2016
Contract No. 8—BAF Plumbing – NTP Issued May 27, 2016
Contract No. 9 – Secant Pile Contract – Completion anticipated in September 2016
Contract No. 10 - 13 –Solids Handling Renovation
Floodwall –Floodwall and New Diversion Structure
Contract No. 1 - Compost Facility Demolition
Demolition of the upper portion of the compost facility was performed to accommodate the construction of the new Administration Building to house the plant staff as well as provide the new control room to operate the new facilities. The lower portion of the Compost Building is being converted into a new Maintenance Building.
Contract No. 2 – FEMA Mechanical
The FEMA Mechanical Project replaces valves, equipment and other miscellaneous items damaged in the 2011 flood. It includes equipment in both the East and West Primary Sludge Pumping Stations, valves and equipment located in the Head House, and equipment associated with Sludge Thickener Pumping Station Nos. 1 and 2. Work associated with this contract is being reimbursed by FEMA due to the flood of 2011.
Contract No. 3 - BAF Facility Demolition
The BAF Demolition Contract removed the existing structures and utilities that conflict with the new construction work included in the BAF Restoration Project. Demolition efforts include selective demolition in the existing process tanks (C-Filters, N-Filters, and DN-Filters) and buildings and mechanical equipment and piping to ready the site for new construction.
Contract No. 4 – MCC - HH Emergency Replacement
Replacement of the existing Motor Control Center (MCC) Head House (HH) includes replacement of the existing 50 year old equipment including new electrical feeders from the HH to the Johnson City Grit House No. 1, a new feeder from the HH to the Thickened Sludge Pump Station No. 1, and various other panelboards. The emergency work also includes replacement of the existing raw sewage variable frequency drives that run the raw sewage pumps.
Contract No. 5 – BAF Restoration and Rehabilitation Civil Contract
The BAF General Civil contract is intended to provide a functioning automated plant using a BIOSTYR system that can be modified to fit current plant configurations. It is also intended to provide functioning automated headworks and primary clarification processes upstream of the BIOSTYR system and solid handling processes downstream of the BIOSTYR system.
Major components of the work under Contract No. 5 include new coarse screens and ancillary equipment, new piping and valves for the influent pumps, new metering equipment, new fine screens and grit removal with ancillary equipment, a new primary distribution box, new mechanical equipment for primary clarifiers 1-10, new chemical equipment for primary treatment, modification of the primary clarifier structural components to reverse the direction of flow, new secondary influent pumps for the new BAF system, a new BAF backwash tank, new CN-BAF and DN-BAF facilities, new methanol system that feeds the DN-BAF cells, new Ultra Violet Light disinfection system to replace the existing chlorine disinfection system, new sludge thickening equipment and systems, a new administration building, new odor control equipment, two new 2MW electric generators, and a new outfall from the STP to the river.
Contract No. 6 – BAF Electrical
The BAF Electrical contract includes all electrical and instrumentation associated with the construction of the components included in the General Civil Contract, the HVAC Contract, and the Plumbing Contract. The components include installation of the new UV disinfection system, installation of the new generators, installation of the electrical feed throughout the plant, as well as installation of the instrumentation and SCADA System throughout the plant.
Contract No. 7—BAF HVAC
The BAF HVAC contract includes installation of all HVAC Systems in all STP Facilities as well as revisions to the odor control systems throughout the plant. The odor control improvements are intended to alleviate the odors that have been prevalent in the past in and around the plant.
Contract No. 8—BAF Plumbing
The BAF Plumbing contract includes installation of plumbing systems for the new and existing facilities included in Contract No. 5.
Contract No. 9 – Secant Pile Contract
The Secant Pile contract includes installation of the secant piles that support the excavation for the new BAF Backwash tank as well as supporting the new CN Cells 9-14. Construction also includes excavation to the final grade for the BAF Backwash tank, and is progressing with the installation of the piles as well as construction the intermediate lateral and vertical support beams.
Contract No. 10 - 13 –Solids Handling Renovation
Contracts No. 10-13 are intended to renovate and improve the solids handlings systems including the existing digester control building, existing digesters, solids dewatering systems, and all ancillary equipment.
The new floodwall being constructed at the STP is intended to protect the plant to an elevation 1.5 feet above the 2011 flood level. The floodwall includes concrete walls on the east and north side of the STP. The project also includes two new pump stations to pump rainwater out of the plant during the storm events that exceed the existing storm drain system. The new flood wall system works in conjunction with new flood wall systems included in Contract No. 5 BAF General Civil Construction. The flood wall systems are being funded by a FEMA recovery grant.